Interchangeable swivel combined multicoupler

ABSTRACT

The present disclosure generally relates to a combined multicoupler for connecting a tool to a top drive. The combined multicoupler includes a load frame comprising a frame body having a load shoulder, and a side door coupled to the frame body. The side door opens from the frame body to allow a tool sliding horizontally into the load shoulder, and the side door closes to lock the tool in the load frame. The combined multicoupler further comprises a drive stem movably coupled to the load frame, wherein the drive stem moves vertically to connect and disconnect with the tool in the load frame.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application is a division of U.S. patent application Ser. No.15/607,159 filed on May 26, 2017. The aforementioned patent applicationis herein incorporated by reference in its entirety.

BACKGROUND OF THE DISCLOSURE Field of the Disclosure

The present disclosure generally relates to a combined multicoupler fora top drive.

Description of the Related Art

A wellbore is formed to access hydrocarbon-bearing formations (e.g.,crude oil and/or natural gas) or for geothermal power generation by theuse of drilling. Drilling is accomplished by utilizing a drill bit thatis mounted on the end of a drill string. To drill within the wellbore toa predetermined depth, the drill string is often rotated by a top driveon a drilling rig. After drilling to a predetermined depth, the drillstring and drill bit are removed and a string of casing is lowered intothe wellbore. An annulus is thus formed between the casing string andthe wellbore. The casing string is hung from the wellhead. A cementingoperation is then conducted in order to fill the annulus with cement.The casing string is cemented into the wellbore by circulating cementinto the annulus defined between the outer wall of the casing and theborehole. The combination of cement and casing strengthens the wellboreand facilitates the isolation of certain areas of the formation behindthe casing for the production of hydrocarbons.

During a drilling and well construction operation, various tools areused which have to be attached to the top drive. The process of changingtools is very time consuming and dangerous requiring personnel to workat heights.

Therefore, there is a need for a coupler for quickly connecting anddisconnect the top drive and various tools.

SUMMARY OF THE DISCLOSURE

The present disclosure generally relates to a combined multicoupler forconnecting a tool to a top drive.

One embodiment of the present disclosure provides a coupler for a topdrive. The coupler includes a load frame having a frame body having aload shoulder, and a side door coupled to the frame body. The side dooropens from the frame body to allow a tool sliding horizontally into theload shoulder, and the side door closes to lock the tool in the loadframe. The coupler further includes a drive stem movably coupled to theload frame, wherein the drive stem moves vertically to connect anddisconnect with the tool in the load frame.

Another embodiment of the present disclosure provides a tool dock forconnecting a tool to a top drive. The tool dock includes a housinghaving a load shoulder formed on an outer surface, a drive sleeverotatably disposed in the housing, wherein the drive sleeve has a loadprofile and a central bore for receiving a tool mandrel therein, and ahydraulic swivel attached to the housing.

Another embodiment provides a method for connecting a tool to a topdrive. The method includes moving a tool having to a tool dockhorizontally to slide the tool dock into a load shoulder of a load frameand couple a hydraulic multicoupler on the tool with a hydraulicmulticoupler on the load frame, closing a side door of the load frame tolock the tool into the load frame, and lowering a drive stem towards tothe tool dock to connect the drive stem to the tool dock.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the presentdisclosure can be understood in detail, a more particular description ofthe disclosure, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this disclosure and are therefore not to beconsidered limiting of its scope, for the disclosure may admit to otherequally effective embodiments.

FIG. 1 is a schematic perspective view of a combined multicoupler systemaccording to one embodiment of the present disclosure.

FIG. 2A is a perspective view of a load frame according to oneembodiment of the present disclosure.

FIGS. 2B and 2C are sectional side views of the load frame of FIG. 2A.

FIG. 2D is a sectional top view of the load frame of FIG. 2A.

FIG. 2E is a perspective view of a door actuating assembly of the loadframe of FIG. 2A.

FIG. 2F is a perspective view of a gear assembly of the door actuatingassembly of FIG. 2E.

FIG. 2G is a perspective view of a pin puller assembly of the load frameof FIG. 2A.

FIG. 3A is a perspective view of a tool dock according to one embodimentof the present disclosure.

FIGS. 3B and 3C are sectional side views of the tool dock of FIG. 3A.

FIG. 3D is a top view of the tool dock of FIG. 3A.

FIG. 3E is a partial enlarged view of the tool dock of FIG. 3A showing ahydraulic multicoupler.

FIG. 4A is a perspective view of a drive stem according to oneembodiment of the present disclosure.

FIGS. 4B and 4C are sectional side views of the drive stem of FIG. 4A.

FIG. 4D is a top view of the drive stem of FIG. 4A.

FIG. 4E is a sectional top view of the drive stem of FIG. 4A.

FIG. 4F is a sectional side view of the drive stem of FIG. 4A showingalignment rails.

FIGS. 5A-5E schematically illustrate a sequence coupling the tool dockto the load frame in the combined multicoupler system.

FIG. 6A-6E schematically illustrate a sequence coupling the drive stemto the tool dock in the combined multicoupler system.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements disclosed in oneembodiment may be beneficially utilized on other embodiments withoutspecific recitation. The drawings referred to here should not beunderstood as being drawn to scale unless specifically noted. Also, thedrawings are often simplified and details or components omitted forclarity of presentation and explanation. The drawings and discussionserve to explain principles discussed below, where like designationsdenote like elements.

DETAILED DESCRIPTION

FIG. 1 is a schematic perspective view of a combined multicoupler system100 according to one embodiment of the present disclosure. The combinedmulticoupler system 100 includes a load frame 120 for connecting to ahook on a derrick. A tool dock 130 may be inserted into the load frame120. The tool dock 130 is configured to house a tool, such as a toolattached to a. The load frame 120 may have a load shoulder to transferaxial load from a drilling string attached to the tool dock 130 to thederrick. The combined multicoupler system 100 further includes a drivestem 140. The drive stem 140 may be movably coupled to the load frame120. The drive stem 140 may move relative to the load frame 120 along avertical axis 101 to connect with or disconnect from the tool dock 130.When connected to the tool dock 130, the drive stem 140 may transfertorsional load to the tool dock 130.

FIG. 2A is a perspective view of the load frame 120 according to oneembodiment of the present disclosure. FIGS. 2B and 2C are sectional sideviews of the load frame 120. FIG. 2D is a sectional top view of the loadframe 120.

The load frame 120 includes a C-shaped frame body 202 and a side door204. A load shoulder 224 is formed in the frame body 202 and the sidedoor 204 for receiving the tool dock 130 and transferring axial loads.The frame body 202 and the side door 204 is movably coupled together,such as by a hinge pin 216, so that the side door 204 can be opened andclosed. When the side door 204 is in an open position, as shown in FIG.1 , a tool dock, such as the tool dock 130, can be inserted or removedfrom the load frame 120 by moving along a horizontal direction into theframe body 202. The side door 204 is closed, as shown in FIG. 2A, tohold the tool dock 130 for operation.

In one embodiment, the load frame 120 includes a door actuating assembly206 for automatically opening and closing the side door 204. In oneembodiment, the door actuating assembly 206 includes an actuator 220 anda gear assembly 222.

In one embodiment, a locking pin 218 is inserted through the frame body202 and the side door 204 to lock the side door 204 in the closedposition. In one embodiment, the load frame 120 includes a pin pullerassembly 208 that is used to insert the locking pin 218 to lock the sidedoor 204 and to pull the locking pin 218 to unlock the side door 204. Inone embodiment, the pin puller assembly 208 includes a hydraulicactuator to move the locking pin 218.

The load frame 120 may include one or more linkages 210 for connectingto the load frame 120 to a derrick. In one embodiment, the linkage 210has two link arms 210 attached to the frame body 202. Each link arm 210is connected to the frame body 202 through a link pin 226 at one end.Each link arm 210 include a link structure, such as a through hole 228,on another end. The through hole 228 receives a link pin to connect withthe derrick, such as a travelling block on the derrick.

In one embodiment, the load frame 120 includes a proximity sensor array238. The proximity sensor array 238 may be disposed on the frame body202. The proximity sensor array 238 can be used to detect a position ofa tool dock being installed or to measure a distance of the tool dockbeing installed. When the tool dock is in position, the side door 204can be closed so the tool dock can be securely positioned in the loadframe 120.

The load frame 120 may further include a drive support 230 forsupporting a drive unit 212. The drive support 230 may be a ring shapedbody coupled between the link arms 210. FIG. 2E is a perspective viewthe load frame 120 showing the support 230 with the drive unit 212removed. The drive unit 212 may include one or more electric motors. Inone embodiment, a gear box 214 may be connected to the drive unit 212.The gear box 214 may be used to connect the motors to a drive stem, suchas the drive stem 140. The drive unit 212 may be used to rotate thedrive stem attached thereto.

In one embodiment, the load frame 120 includes a guide rail 232 to guidevertical movements of a drive stem attached to the drive unit 212. Theguide rail 232 may be fixedly attached to the frame body 202. The drivestem 140 may move up along the guide rail 232 to allow removal andinstallation of a tool dock.

In one embodiment, the load frame 120 further includes a hydraulicmulticoupler 234. The hydraulic multicoupler 234 may be attached to abracket 236. The bracket 236 may be attached to the frame body 202. Thebracket 236 may extend downward from the frame body 202. The hydraulicmulticoupler 234 is positioned to couple with a hydraulic manifold on atool dock when the tool dock is connected to the load frame 120. In oneembodiment, the hydraulic multicoupler 234 may be mounted on a sphericalbearing to accommodate misalignment between the tool dock and the loadframe 120.

FIG. 2E is a perspective view of the load frame 120 showing the sidedoor 204 in the open position. The side door 204 may swing open or closerelative to the frame body 202 by the door actuating assembly 206. Thegear assembly 222 of the door actuating assembly 206 may be disposed onthe frame body 202 and the side door 204. FIG. 2F is a partialperspective view of the gear assembly 222 of the door actuating assemblyof FIG. 2E.

The gear assembly 222 may include a drive gear 244 meshed with a drivengear 246. In FIG. 2F, the drive gear 244 is disposed on the side door204 and the driven gear 246 is disposed on the frame body 202.Alternatively, the drive gear 244 may be disposed on the frame body 202and the driven gear 246 may be disposed on the side door 206. As shownin FIG. 2F, the drive gear 244 is connected to the actuator 220. In oneembodiment, the actuator 220 may be a rotary hydraulic actuator. Theactuator 220 may rotate the drive gear 244 causing the side door 204 toswing open or close through the coupling between the drive gear 244 andthe driven gear 246. In one embodiment, the drive gear 244 may befurther coupled to an idle gear 248. The idle gear 248 is furthercoupled to a turns counter 250. The turns counter 250 may be used tosense intermittent positions of the side doors 204 while the side door206 is being opened or being closed.

FIG. 2G is a partial exploded view of the load frame 120 showing the pinpuller assembly 208. The pin puller assembly 208 may include acantilever arm 252. A hydraulic cylinder 254 may be connected to thecantilever arm 252 to move raise and lower the cantilever arm 252. Thelock pin 218 is attached to the cantilever arm 252. Movements of thecantilever arm 252 pull the lock pin 218 from the frame body 202 orinsert the lock pin 218 into the frame body 202. The side door 204 has athrough hole 240 formed at an end. When the side door 204 is closed, thethrough hole 240 aligns with through holes 242 in the frame body 202 sothat the lock pin 218 may be inserted through the through holes 240 and242 to lock the side door 204 to the frame body 202 at the closedposition.

In one embodiment, the load frame 120 may also include a sensor assembly258 disposed on or near the pin puller assembly 208. The sensor assembly258 may include one or more proximity sensors to confirm that the sidedoor 204 is closed. The sensor assembly 258 may also include one or morelinear transducers configured to detect intermittent positions of thelock pin 218 during locking or unlocking of the side door 204. In oneembodiment, the sensor assembly 258 may include a proximity sensorpositioned to sense the lock pin 218 when the lock pin 218 is insertedtherethrough the through holes 240, 242, therefore confirming locking ofthe side door 204.

FIG. 3A is a perspective view of the tool dock 130 according to oneembodiment of the present disclosure. FIGS. 3B and 3C are sectional sideviews of the tool dock 130. FIG. 3D is a top view of the tool dock 130.

The tool dock 130 may include a housing 302. The housing 302 may be atubular having an outer shoulder 308 and an inner shoulder 310. Thehousing 302 may include a central bore 312. The outer shoulder 308 maybe inserted into the load shoulder 224 of the load frame 120 when thetool dock 130 is installed in the load frame 120.

The tool dock 130 further includes a drive sleeve 306 disposed in thehousing 302. A thrust bearing 314 may be disposed on the inner shoulder310 in the housing 302. A lower end 306 a of the drive sleeve 306 isdisposed on the thrust bearing 314. The thrust bearing 314 transfersaxial loads between the housing 302 and the drive sleeve 306. A radialbearing 316 may be disposed between an outer surface 306 b of the drivesleeve 306 and an inner surface 302 a of the housing 302. The radialbearing allows rotation between the drive sleeve 306 and the housing302. A top cover 322 may be fixedly attached to the housing 302 toprevent the radial bearing 316 and the drive sleeve 306 from movingaxially relative to the housing 302.

An upper end 306 c of the drive sleeve 306 extends from the housing 302.The upper end 306 c may be coupled with a drive stem, such as the drivestem 140, to transfer axial and torsional loads from the drive stem. Theupper end 306 a may have a torque transfer profile 318 for transferringtorsional loads to and from the stem drive 140. In one embodiment, thetorque transfer profile 318 may be a bayonet profile. The upper end 306a may further include an axial load profile 320 for transferring axialloads to and from the stem drive 140. In one embodiment, the axial loadprofile 320 may be a groove for receiving one or more load bearingballs.

A tool mandrel 304 may be coupled to the drive sleeve 306. The toolmandrel 304 may be a part of or be connected to any tools that can beused with a top drive, such as a drilling tool, a casing tool, acementing tool, a completion tool, a fracturing tool, a pump, a sandscreen, a clamping tool, an internal gripping tool, an external grippingtool, an adaptor, or a combination thereof. The tool mandrel 304 mayinclude a central bore 333 for providing a fluid communication fordrilling fluid, cement, and other well construction fluids.

In one embodiment, the tool mandrel 304 may be coupled to the drivesleeve 306 by a threaded connection 324. The threaded connection 342transfers axial loads between the drive sleeve 306 and the tool mandrel304. A lower end 304 a of the tool mandrel 304 may extend from thehousing 302. In one embodiment, the lower end 304 a may include aconnection feature for connecting with a workstring or a tool.

An upper end 304 b of the tool mandrel 304 extends into the top end 306c of the drive sleeve 306. In one embodiment, the tool mandrel 304includes a torsional load transfer profile 326 for transferringtorsional loads between the load mandrel 304 and the drive sleeve 306.The drive sleeve 306 may also include a torsional load transfer profile328 formed on the upper end 306 c. In one embodiment, the torsional loadtransfer profiles 326, 328 may be key ways for receiving one or moretorque keys 330 therein.

In one embodiment, the tool dock 130 further includes a hydraulic swivel332 for providing hydraulic fluid to the tool. The hydraulic swivel 332may include a rotating sleeve 336 attached to the tool mandrel 304 and astationary sleeve 338 attached to the housing 302. When the tool mandrel304 rotates relative to the housing 302, the rotating sleeve 336 rotatesrelative to the stationary sleeve 338. One or more fluid paths 340 maybe formed between the stationary sleeve 338 and the rotating sleeve 336.In one embodiment, the tool dock 130 may include a swivel sleeve 334attached on an outer surface of the tool mandrel 304. The rotatingsleeve 336 may be attached to a flange 342 of the swivel sleeve 334.

A hydraulic multicoupler 344 may be attached to the housing 304 or tothe stationary sleeve 338. FIG. 3E is a partial enlarged view of thetool dock 130 showing the hydraulic multicoupler 344. The hydraulicmulticoupler 344 may include a housing 348 having one or more hydraulicconnector 346 disposed therein. Each hydraulic connector 346 may beconnected to one of the fluid path 340.

The housing 348 may be connected to the housing 304 or the stationarysleeve 338 by a spherical bearing 350. The spherical bearing 350 allowsthe housing 348 to rotate along three axes to enable alignment betweenthe hydraulic multicoupler 344 and the hydraulic multicoupler 234 on theload frame 120.

FIG. 4A is a perspective view of the drive stem 140 according to oneembodiment of the present disclosure. FIGS. 4B and 4C are sectional sideviews of the drive stem 140. FIG. 4D is a top view of the drive stem140.

The drive stem 140 include a stem shaft 402. An index plate 404 may becoupled to the drive shaft 402. The index plate 404 may be coupled to anouter diameter of the drive shaft 402 by a bearing 405 so that the driveshaft 402 is rotatable relative to the index plate 404. The index plate404 and the drive shaft 402 do not move relative to each other on thelongitudinal direction along a central axis 401.

A locking sleeve 408 may be movably attached to the drive shaft 402. Anactuation plate 406 may be coupled to the locking sleeve 408. Theactuation plate 406 may be coupled to an outer diameter of the lockingsleeve 408 by a bearing 407 so that the locking sleeve 408 is rotatablerelative to the actuation plate 406. The actuation plate 406 and thelocking sleeve 408 do not move relative to each other on thelongitudinal direction along the central axis 401.

One or more actuator 412 may be coupled between the index plate 404 andthe actuation plate 406 to move the actuation plate 406 and the lockingsleeve 408 relative to the drive shaft 402. In one embodiment, the oneor more actuator 412 may be one or more pneumatic cylinder. In oneembodiment, the one or more actuator 412 may be coupled between one ormore tab 414 of the index plate 404 and one or more tab 416 of theactuation plate 406. As shown in FIG. 4A, the drive stem 140 may includetwo actuators 412. The two actuators 412 may be connected to the indexplate 404 at 180° from each other to provide symmetric actuation.

In one embodiment, the drive stem 140 may include one or more alignmentrail 430 disposed between the index plate 404 and the actuation plate406. FIG. 4F is a sectional side view of the drive stem of FIG. 4Ashowing the alignment rails 430. In one embodiment, the drive stem 140may include four alignment rails 430 distributed about 90° from eachother, as shown in FIG. 4D.

In one embodiment, the drive stem 140 may include guide openings 418,420 configured to guide linear movement of the drive stem 140. The guideopening 418 may be formed through the index plate 404. The guide opening420 may be formed through the actuation plate 406. The guide openings418, 420 may be aligned along a line parallel to the central axis 401 ofthe drive stem 140. When the drive stem 140 is installed on the loadframe 120, the guide openings 418, 420 receive the guide post 232 of theload frame 120 to direct vertical movements of the drive stem 140. Inone embodiment, one or more bearings 422 may be disposed in the guideopening 418, 420.

The stem shaft 402 may include a central bore 410. The stem shaft 402 isconfigured to connect a drive unit, such as the drive unit 212, to atool dock, such as the tool dock 130. The stem shaft 402 transferstorsional loads between the drive unit and the tool dock. The centralbore 410 is configured to provide a fluid path for working fluids, suchas mud, cement, and other well construction fluids.

The stem shaft 402 may include an upper end 402 a configured to connectwith a drive unit and a lower end 402 b configured to connect with atool dock. The lower end 402 b may have an outer diameter larger than anouter diameter of the upper end 402 a. A tool receiving opening 436 isformed in the lower end 402 b. The tool receiving opening 436 may beshaped to receive a tool dock, such as the tool dock 130.

A torque transfer profile 428 formed in an inner surface of the toolreceiving opening 436. FIG. 4E is a sectional top view of the drive stem140 showing the torque transfer profile 428 according to one embodimentof the present disclosure. The torque transfer profile 428 may includeone or more torque keys 426 formed on the inner surface of the stemshaft 402.

In one embodiment, a plurality of through holes 434 may be formedthrough the stem shaft 402 at the lower end 402 b. A lock element 432 ismovably disposed in each through hole 434. In one embodiment, the lockelement 432 may be a lock ball. Alternatively, the lock element 432 maybe in other shapes, such as a cylinder. When the locking sleeve 408moves down to a locked position, as shown in FIGS. 4B and 4C, the lockelements 432 are pushed radially inward into the tool receiving opening436 by the locking sleeve 408, thereby, forming an axial load profile tolock a tool dock in an axial position. When the locking sleeve 408 movesup to an unlock position, the lock elements 432 may be pushed radiallyoutward to allow a tool dock in or out the tool receiving opening 436.

A pipe portion 402 c is formed in the tool receiving opening 436. When atool dock is inserted in the tool receiving opening 436, the pipeportion 402 c may be inserted into a central bore of the tool dock toform a fluid path between the central bore 410 and the central bore ofthe tool dock. In one embodiment, one or more seal element may bedisposed on an outer surface of the pipe portion 402 to form a sealedfluid connection with a tool dock.

FIGS. 5A-5E schematically illustrate a sequence coupling the tool dock130 to the load frame 120 in the combined multicoupler system 100. Theside door 204 of the load frame 120 is open and the drive stem 140 israised to receive the tool dock 130. The tool dock 130 may be movedadjacent to the load frame 120 and aligned with the load frame 120 sothat the outer shoulder 308 of the tool dock 130 may be inserted intothe load shoulder 224 of the load frame 120. In one embodiment, theouter shoulder 308 and/or the load shoulder 224 may have guidancechamfers formed thereon to provide tolerance in alignment. In oneembodiment, the tool dock 130 may be misaligned with the load frame 120for about ±0.25 inch (or about ±6.5 mm) in vertical and horizontaldirections. The proximate sensor array 238 on the load frame 120 may beused to align the tool dock 130 and the load frame 120.

In one embodiment, the alignment of the tool dock 130 may includeadjusting the orientation of the tool dock 130 to align the hydraulicmulticoupler 344 on the tool dock 130 with the hydraulic multicoupler244 on the load frame 120.

After the tool dock 130 is aligned with the load frame 120, the tooldock 130 may be inserted into the load frame 120 as shown in FIG. 5A. Inone embodiment, the proximate sensor array 238 on the load frame 120 maybe used to detect the relative position of the tool dock 130 duringinserting. When the tool dock 130 is inserted in the load frame 120, thehydraulic multicoupler 344 on the tool dock 130 is also coupled to thehydraulic multicoupler 234 on the load frame 120.

After the tool dock 130 is inserted into the load frame 120, the sidedoor 204 may be closed to secure the tool dock 130 in the load frame 120as shown in FIG. 5C. The turns counter 250 on the door actuatingassembly 206 may be used to intermittent positions of the side door 204.The turns counter 250 may be used to determine whether the side door 204is closed. In one embodiment, one or more proximity sensors in thesensor assembly 258 may sense the position of the side door 204 toconfirm that the side door 204 is closed.

Upon confirmation that the side door 204 is closed, the pin pullerassembly 208 may lower the lock pin 218 down to lock the side door 204to the frame body 202. FIG. 5C is a perspective view of the pin pullerassembly 208 with the lock pin 218 in an intermittent position. FIG. 5Dis a perspective view of the pin puller assembly 208 with the lock pin218 in a locked position. In one embodiment, a linear transducer 256 inthe sensor assembly 258 may be used to monitor the intermittentpositions of the lock pin 218. FIG. 5E schematically illustrates thelinear transducer 256. The linear transducer 256 may be used todetermine whether the lock pin 218 is in the locking position. In oneembodiment, one or more proximity sensors 260, shown in FIG. 5D, in thesensor assembly 258 may be used to detect the lock pin 218 in thelocking position, therefore confirming that the side door 204 has beenlocked.

After the tool dock 130 is coupled to the load frame 120, the drive stem140 may be coupled to the tool dock 130 for operation. FIG. 6A-6Eschematically illustrate a sequence coupling the drive stem 140 to thetool dock 130 in the combined multicoupler system 100.

FIG. 6A is a schematic side view of the combined multicoupler system 100after the tool dock 130 is coupled to the load frame 120 and prior tothe tool dock 130 is coupled to the drive stem 140. The drive stem 140is clear from the tool dock 130. The locking sleeve 408 is raised to theunlocked position. At the position shown in FIG. 6A, the drive stem 140may be rotated to align the torque keys 426 with the torque transferprofile 318 on the tool dock 130.

The drive stem 140 may then be lowered toward the tool dock 130 to forma connection therebetween. While lowering the drive stem 140, theproximity sensor array 238 on the load frame 120 may be used to sensingthe position of the drive stem 140. FIG. 6B is a schematic perspectiveview of the combined multicoupler system 100 showing the proximitysensor array 238 relative to the drive stem 140. In one embodiment, theproximity sensor array 238 may be used to sensing the position of theactuation plate 406 to determine the final position of the drive stem140.

FIGS. 6C-6D are schematic sectional views of the coupling sequencebetween the drive stem 140 and the tool dock 130. In FIG. 6C, the drivestem 140 is being moved downwardly so that the pipe portion 402 c of thedrive stem 140 is inserted into the central bore 333 of the tool dock130, and the torque keys 426 of the drive stem 140 mate with the torquetransfer profile 318 of the tool dock 130. The vertical movement of thedrive stem 140 may be guided by the guide rail 232.

In FIG. 6D, the drive shaft 402 of the drive stem 140 is moved to thetarget position wherein the torque keys 426 are coupled with the torquetransfer profile 318 and the locking elements 432 are aligned with theaxial load transfer profile 320. The target position of the drive stem140 may be monitored and sensed by the proximity sensor array 238. Inthis position, a fluid path is formed between the central bores 410 and332, and a torque load transfer path is formed between the torque keys426 and the torque transfer profile 318.

In FIG. 6E, the locking sleeve 408 is lowered to push the lockingelements 432 into the axial load profile 320. The actuation plate 406may move with the locking sleeve 408. The proximity sensor array 238 maybe used to detect the position of the actuation plate 406 to determinewhether the locking sleeve 408 is in the locked position. The lockingelements 432 protrude into the axial load profile 320 thereforeproviding an axial load transfer path between the tool dock 130 and thedrive stem 120.

Embodiments of the present disclosure provide a coupler for a top drive.The coupler includes a load frame comprising a frame body having a loadshoulder, and a side door coupled to the frame body, wherein the sidedoor opens from the frame body to allow a tool to move horizontally intothe frame body, and the side door closes to lock the tool in the loadframe, and a drive stem movably coupled to the load frame, wherein thedrive stem moves vertically to connect and disconnect with the tool inthe load frame.

In one or more embodiment, the load frame further comprises a hydraulicmulticoupler attached to the frame body, wherein the hydraulicmulticoupler is positioned to connect with a hydraulic multicoupler onthe tool when the tool is inserted into the load shoulder.

In one or more embodiment, the coupler further includes a door actuatingassembly coupled to the side door and the frame body, wherein the dooractuating assembly automatically opens and closes the side door.

In one or more embodiment, the door actuating assembly comprises a gearassembly connected to the side door, and a motor attached to the gearassembly.

In one or more embodiment, the door actuating assembly further comprisesa turns counter coupled to the gear assembly, wherein the turns counteris configured to monitor positions of the side door.

In one or more embodiment, the coupler further includes one or moreproximity sensors positioned to detect the side door at the closedposition.

In one or more embodiment, the coupler further includes a pin pullerassembly for inserting a lock pin between the side door and the loadframe when the side door is at the closed position.

In one or more embodiment, the coupler further includes a lineartransducer positioned to sensing intermittent positions of the lock pin.

In one or more embodiment, the coupler further includes a sensorassembly attached to the frame body, wherein the sensor assemblycomprises one or more proximity sensors positioned to detect positionsof the drive stem.

In one or more embodiment, the coupler further includes furthercomprising a drive unit connected with the load frame, wherein the driveunit is coupled to the drive stem.

In one or more embodiment, the drive stem comprises a drive shaft havinga tool receiving opening and a torque profile, a plurality of lockingelements movably disposed in the drive shaft, and a locking sleevedisposed over the drive shaft, wherein the locking sleeve is movablebetween a lock position and a unlock position, the locking sleeve pushesthe plurality of locking elements radially inward at the lock positionand release the locking elements at the unlock position.

In one or more embodiment, the drive stem further comprises an indexplate rotatably coupled to the drive shaft, an actuation plate rotatablycoupled to the locking sleeve, and an actuator coupled between the indexplate and the actuation plate to move the index plate relative to theactuation plate along an axial direction.

In one or more embodiment, the drive stem further comprises one or morealignment rail disposed between the actuation plate and the index plate.

In one or more embodiment, the load frame comprises a guide rail alongthe axial direction, and the index plate and the actuator plate includealignment openings receiving the guide rail.

Some embodiments of the present disclosure provide a tool dock forconnecting a tool to a top drive. The tool dock includes a housinghaving a load shoulder formed on an outer surface, a drive sleeverotatably disposed in the housing, wherein the drive sleeve has a loadprofile and a central bore for receiving a tool mandrel therein, and ahydraulic swivel attached to the housing.

In one or more embodiment, the load profile includes a groove formed theouter surface of the drive sleeve for receiving one or more load bearingelements, and torque keys formed on the drive sleeve.

In one or more embodiment, the housing has a threaded portion formed onan inner surface the housing for forming a threaded connection with thetool mandrel.

In one or more embodiment, the tool dock further includes one or moretorque keys for torsionally coupling the drive sleeve to the toolmandrel.

Some embodiments of the present disclosure provide a method forconnecting a tool to a top drive. The method includes horizontallymoving a tool connected to a tool dock into a load frame coupled to thetop drive, closing a side door of the load frame to lock the tool in theload frame, and lowering a drive stem towards to the tool dock toconnect the drive stem to the tool dock.

In one or more embodiment, moving the tool comprises: aligning the tooldock with the load frame, and sliding the tool dock into the loadshoulder.

In one or more embodiment, lowering the drive stem comprises aligning atorque transfer profile on the tool dock with a torque transfer profileon the drive stem, lowering the drive stem to the tool dock totorsionally couple the drive stem to the tool dock, and moving one ormore locking elements of the drive stem into an axial load transferprofile on the tool dock.

In one or more embodiment, moving the one or more locking elementscomprises moving a locking sleeve disposed over the drive stem to pushthe one or more locking elements toward the tool dock.

In one or more embodiment, the method further includes coupling ahydraulic multicoupler on the tool with a hydraulic multicoupler on theload frame.

While the foregoing is directed to embodiments of the presentdisclosure, other and further embodiments of the disclosure may bedevised without departing from the basic scope thereof, and the scope ofthe invention is determined by the claims that follow.

The invention claimed is:
 1. A tool dock for connecting a tool to a topdrive, comprising: a housing having a load shoulder formed on an outersurface thereof configured to transfer an axial load from the tool dockto a frame body of the top drive; a drive sleeve rotatably disposed inthe housing, wherein the drive sleeve has a load profile and a centralbore for receiving a tool mandrel therein; a hydraulic swivel attachedto the housing configured to provide hydraulic fluid to the tool;wherein the hydraulic swivel includes a rotating sleeve and stationarysleeve; and wherein one or more flow paths are formed between thestationary sleeve and the rotating sleeve, wherein the rotating sleeveis attached to a flange of a swivel sleeve.
 2. The tool dock of claim 1,wherein the load profile includes: a groove formed on the outer surfaceof the drive sleeve for receiving one or more load bearing elements; andtorque keys formed on the drive sleeve.
 3. The tool dock of claim 1,wherein the housing has a threaded portion formed on an inner surface ofthe housing for forming a threaded connection with the tool mandrel. 4.The tool dock of claim 1, further comprising one or more torque keys fortorsionally coupling the drive sleeve to the tool mandrel.
 5. The tooldock of claim 1, wherein the tool mandrel is either a part of orconnectable to the tool.
 6. The tool dock of claim 5, wherein the toolmandrel is part of the tool.
 7. The tool dock of claim 1, wherein thetool is selected from the group consisting of a drilling tool, a casingtool, a cementing tool, a completion tool, a fracturing tool, a pump, asand screen, a clamping tool, an internal gripping tool, an externalgripping tool, an adaptor, and combinations thereof.
 8. The tool dock ofclaim 1, further comprising a thrust bearing disposed within the housingbetween the drive sleeve and the housing.
 9. The tool dock of claim 1,further comprising a radial bearing disposed within the housing betweenthe drive sleeve and the housing, wherein the radial bearing isconfigured to facilitate rotation between the drive sleeve and thehousing.
 10. The tool dock of claim 9, further comprising a coverfixedly attached to the housing to prevent the radial bearing and thedrive sleeve from moving axially relative to the housing.
 11. The tooldock of claim 1, wherein the load profile is a bayonet profile.
 12. Thetool dock of claim 1, wherein the load profile is a first load profile,and wherein the drive sleeve further includes a second load profile onan upper end of the drive sleeve, the second load profile configured totransfer axial loads.
 13. The tool dock of claim 1, further comprising ahydraulic multicoupler, the hydraulic multicoupler including one or morehydraulic connectors connected to the one or more flow paths formedbetween the stationary sleeve and the rotating sleeve.
 14. The tool dockof claim 13, wherein the hydraulic multicoupler is attached to thehousing or the stationary sleeve.
 15. The tool dock of claim 1, furthercomprising a swivel sleeve.
 16. The tool dock of claim 1, furthercomprising a hydraulic multicoupler, the hydraulic multicouplerincluding: a hydraulic multicoupler housing attached to the housing; andone or more hydraulic connectors in communication with the hydraulicswivel.
 17. A tool dock for connecting a tool to a load frame of a topdrive, comprising: a housing having a downward facing shoulder on anouter surface of the housing configured to engage the load frame of thetop drive to transfer an axial load from the housing to the load frame;a drive sleeve disposed in the housing and rotatable relative to thehousing, the drive sleeve further including: a first end portionextending from the housing, wherein the first end portion includes afirst torque profile on an exterior surface of the first end portion,wherein the drive sleeve is rotatable relative to the housing inresponse to torque applied to the first torque profile; the first endportion further including a second torque profile on an interior surfaceof the first end portion; a first axial load profile on the exteriorsurface of the first end portion, wherein the first axial load profileis configured to transfer and receive axial loads.
 18. The tool dock ofclaim 17, wherein a tool mandrel is disposed in the drive sleeve,wherein the mandrel includes a third torque profile, wherein the secondtorque profile is configured to transfer a torsional load to the thirdtorque profile.
 19. The tool dock of claim 18, wherein a torque key isdisposed between the second torque profile and the third torque profile.20. The tool dock of claim 18, wherein a top surface of the tool mandrelis flush with a top surface of the drive sleeve.